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Research Paper
IMPACTS OF LEAN TOOLS AND TECHNIQUES FOR IMPROVING
MANUFACTURING PERFORMANCE IN GARMENT
MANUFACTURING SCENARIO: A CASE STUDY
G. Vijayakumar, Y. Robinson
1. INTRODUCTION
Implementation of lean manufacturing for most of
the companies is to make profits either directly by
reducing costs or indirectly by maximizing
productivity [1]. One of the most successes of
garment firms in Tiruppur is that they produce
garments with cheap labour cost. This research
makes use of 5s and Pareto analysis, generally in a
garment industries more consideration is given
methodology. According to Tennant and Geoffeliminating Defective items and improvement of
productivity
by
adaptation
of
continuous
improvement process. To improve the growth of
garment firms in positive direction it is important to
ensure the proper utilization of each resource of
firms. Importance of using the lean principles to
eliminate non value added wastes in garment
industry[2].Many garment manufacturing firms of
their economic growth mainly depends minimization
of garment waste to achieve maximum benefit by
implementation of lean tools and techniques in
garments firms. In most of the garment firms, lot of
rejected garments occurs after shipment. These
garment defects may occur due to less quality raw
materials or faulty process or employee informal
behavior. A study by Kayaalp I. and Erdogan, M.
show that more than 75% garment defects are found
in the final inspection coming from sewing
section[3].In the modern world of garment
manufacturing, payable to high competitive of the
global market, different firms have initiated to adopt
lean tools and techniques and practices to minimize
the percentage of defects. Pareto Analysis helps to
determine the defects of garments and classify them
according to their importance. Achieving lowest cost
and shortest lead time are essential to compete in the
global garment market [4]. In this research 5s,
DMAIC and Pareto analysis are used as a lean tool to
minimize the lean wastes in garment firms. 5S is one
of the optimum lean tool and techniques for
eliminating the garment wastes which occurs made
by human, increasing productivity and clear visibility
of non conformances at workplace. Under profile
waste matrix, Pareto analysis helps to identify 86%
of garment waste occurs due to human mistakes. It
graphically describes the relationship between a
given outcome and all factors that influence the
outcome and hence to determine the defects of
garments. Waste and productivity of firms are the
Int J AdvEngg Tech/Vol. VII/Issue II/April-June,2016/251-260
Garment Items
Executive Readymade
Shirts. Design .1
Design.2
Design.3
Design.4
Design.5
Design.6
Design.7
Executive Readymade
Pants Design.1
Design.2
Design.3
Design.4
Design.5
Design.6
Design.7
Design.8
Design.9
Design.10
Executive Readymade TShirts Design.1
Design.2
Design.3
Design.4
Design.5
Design.6
Design.7
Design.8
Design.9
Design.10
Total
Inspected
pieces
Defectives
items
1660
117
1200
140,400
180
1550
711
755
950
1206
320
121
81
86
94
192
78
970
869
1370
965
1569
1415
117370
70389
117820
90710
301248
110370
182
185
179
186
174
181
1006
125
1647
205875
240
1100
1305
1850
1200
1305
1800
900
420
730
144
135
140
180
171
201
89
52
90
1700
175
1287
1167
1467
1647
1692
1287
1751
1767
1167
220
185328
157545
205380
296460
289332
258687
155839
91884
105030
38500
247
242
236
249
254
225
279
220
264
120
1425
1530
1632
1522
1336
1836
1213
1465
1400
31977
147
155
162
150
135
176
124
148
144
3612
267
39249
112
122
155
200
427
269
360
200
197
25654
18910
25110
30000
57645
47344
44640
29600
28368
3259033
125
118
115
109
126
116
120
104
4888
3. Research Methodology
This research focuses abouteight types of lean wastes
of the selected garment firms located at Tiruppur in
India. Lean tools and techniques are used to
minimize wastages of the existing garment scenario
of the selected firms. The information and data
collected were scrutinized and properly arranged so
that further study and analysis could be performed.
Quantitative data were analyzed by using graphs and
tables. Various types of information were given as a
profile-waste matrix. Based on table 1, analysis has
been shown by Pareto Diagram. Based on profile
waste matrix, Pareto analysis helps to identify 82%
of garment waste occurs due to human mistakes.
Through preliminary analysis the most of defective
garment items occurring in cutting, sewing, washing,
packing and finishing section among all sections in
selected garment industry. The collection of data is
analyzed and technique used for problem solving
through DMAIC of Six Sigma methodology and for
achieving productivity excellence. Mostly employee
casual behavior can be reduced by 5S lean tool.
Therefore this research work minimized garment
defectives by implementing 5S.The detail analyses of
following steps are mentioned by the flow diagram in
Fig.1.
Transportatio
n
Defects
Inventory
Over
processing
Motion
Waiting
Under
Utilisation Of
People
Causes
Unlevelled scheduling
Un balanced work load
Lengthy process step
Misuse of automation
Large batch size
Poor plant layout
Large storage area
Poor understanding of the process flow for production
Longer lead times
Seaming defects
Sewing Defects
Placement Defects
Fabric defects
Embroidery defects
Unlevelled scheduling
Poor market forecast
Un balanced work load
Unreliable shipment by suppliers
Styles changes without process changes
Lack of information about process
Customer true requirement not properly defined
Redundant approvals
Over processing to accommodate expected down time
Large items located on upper or lower shelf
A machine that unnecessary travelling distances
Finding necessary equipment and tools for concern production process
Unnecessary motion from work place to retrieve materials or utilize
machines
Unplanned Tools for Work Place
Lack of space in organization in manufacturing area for keeps the
components
Poor scheduling of production process
Time taken for signature approval from higher officials to take require
decision
Improper arrangements of machines for process sequence
In adequate servicing of machines
Challenge of the production manager is to allocate right responsibilities
Challenge of the production manager is to allocate right authorities
Challenge of the production manager is to allocate right jobs
Whether employee possessing high theoretical knowledge is allotted
practice-oriented job
Whether technique used for avoiding under utilization of the people is the
scheduling of their jobs
Man
Responsibilities
Machine
Material
Others
Customers
Amico paradiso canada
Table 4.Percentage of defective garment items before implementing DMAIC and 5S concept
Areas
Man
Machine
Method
Material
Causes
Lack of interest
Improper training and unskilled operator
Excessive thread tension
Bent sewing machine needle
High pressure on the pressure foot
Improper size of the needle
Needle inserted is improper
Long stitch for type of fabric in work
Low quality thread
Low quality needle
Areas
Man
Machine
Method
Material
Solutions
Improve supervision
Skilled operators requirements
Maintain proper thread tensions.
New needle and knife should be replaced
Reduce the pressure on the presser foot.
Make sure that the positions of needle and bottom are
fed by proper type and size
Insert the needle in correct position.
Reduce the length of stitch by using the stitch regulator
High quality thread should be used
Replace another brand with high quality needle
Fig 3.Cause and effect diagram for significant wastes in sewing section
Sample
Dept
Fabric
Stores
Files Arrangement
Floor Marking
Trolleys
Rejection On Floor
Labels
Unnecessary items
Sub Store
Leftover Present
Visual Controls
Pathways Defined
Dust And Stains
Racks And Bins
Visible Sops
No
Partial
Partial
No
No
Yes
No
Yes
No
No
Yes
Yes
No
No
Partial
Yes
Yes
No
Yes
No
Yes
No
No
Yes
Yes
No
No
No
Yes
Yes
No
Yes
No
Yes
No
No
Yes
Yes
No
No
Partial
No
Yes
No
No
No
Yes
No
No
Yes
No
No
No
Partial
Partial
Yes
No
Yes
No
Yes
No
No
Yes
No
No
No
No
No
No
No
Yes
No
Yes
No
No
Yes
No
No
Workers Training
Over 5s
No
No
No
No
No
No
Office
Area
Action
Required
No
No
No
Yes
No
Yes
No
Yes
No
No
Yes
Yes
No
No
No
No
No
No
Yes
No
No
No
No
Yes
Yes
No
Seiton
Seiton
Seiton
Seiri
Seiton
Seiri
Seiton
Seiri
Seiton
Seiketsu
Seiso
Seiton
Seiketsu
No
No
Seiton
Garment Items
Executive Readymade
shirts Design.1
Design.2
Design.3
Design.4
Design.5
Design.6
Design.7
Executive Readymade pants
Design.1
Design.2
Design.3
Design.4
Design.5
Design.6
Design.7
Design.8
Design.9
Design.10
Executive Ready made Tshirts (variety No. One)
Design.2
Design.3
Design.4
Design.5
Design.6
Design.7
Design.8
Design.9
Design.10
Total
Inspected
pieces
Defectives
items
Rate per
piece
Total amount
loss due to
Defective items
Manufacturing
lead time per
piece in
(minutes)
1000
49
1200
58800
165
1150
650
690
828
995
201
60
48
50
54
61
37
970
869
1370
965
1569
1415
58200
41712
68500
52110
95709
52355
167
176
164
171
159
166
900
43
1647
70821
225
750
920
1020
585
1005
1200
200
1050
200
50
26
58
47
46
52
30
45
28
64350
30342
85086
77409
77832
66924
52530
79515
32676
1300
61
1287
1167
1467
1647
1692
1287
1751
1767
1167
220
222
227
221
234
239
210
264
205
249
105
1210
1117
1232
1222
936
1236
913
965
506
23981
48
61
51
35
58
44
52
38
34
1266
267
12816
7442
7905
7000
24766
11836
18720
7600
6698
1183074
CONCLUSION
This case study research has extracted an overall
scenario of the garments of the selected garments
industry for minimizing manufacturing defectives. In
this connection lean manufacturing concept is
implemented as a new concept of manufacturing in
the garments of the studied garments industry. From
5S analysis, it has been found that a lot of
unnecessary items exist in the garment firms like
garment waste material and unwanted tools and
Int J AdvEngg Tech/Vol. VII/Issue II/April-June,2016/251-260
122
155
200
427
269
360
200
197
25654
13420
97
110
103
100
94
111
101
105
89
4479
equipments.
From
DMAIC
methodology
considerable amount of garment defectives are
eliminated. Sometimes garment materials are not put
away immediately after work. The garment worker
will feel more comfortable at work and the
continuous improvement actions will tends to
minimum waste and good quality of items, which
improves the firms competitiveness and profitability.
Before 5s analysis and DMAIC methodology various
types of lean wastes were determined and the causes
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.